Glass enclosure

ABSTRACT

A handheld computing device that includes an enclosure having structural walls formed from a glass material that can be radio-transparent. The enclosure can be formed from a hollow glass tube or two glass members bonded together. A laser frit bonding process may be used to hermetically seal the two glass members together to create a water resistant electronic device.

This application claims priority to and the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/384,211, filed Sep.17, 2010, entitled GLASS ENCLOSURE, the entire disclosure of which ishereby incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The described embodiments relate generally to portable computingdevices. More particularly, the present embodiments relate to enclosuresof portable computing devices and methods of assembling portablecomputing devices.

Description of the Related Art

In recent years, portable electronic devices, such as laptop computers,tablet computers, PDAs, media players, and cellular phones, have becomecompact and lightweight yet powerful. As manufacturers have been able tofabricate various operational components of these devices in smallersizes, the devices themselves have become smaller In most cases, despitehaving a more compact size, such components have increased power as wellas operating speed. Thus, smaller devices may have much morefunctionality and power than larger devices of the past.

One design challenge associated with the portable electronic devices isin techniques for mounting structures within the portable computingdevices. Conventionally, the structures have been laid over one of thecasings (upper or lower) and attached to one of the casings withfasteners, such as screws, bolts, and rivets. That is, the structuresare positioned in a sandwich like manner in layers over the casing andthereafter fastened to the casing. Such an assembly process can be bothtime consuming and cumbersome.

Another design challenge is to provide an aesthetically pleasingenclosure that is functional for the intended purpose of the device.With more devices being capable of wireless communications, a radiotransparent enclosure would be beneficial, as it would allow components,such as antennas, to be positioned inside the enclosure. Users alsodesire an enclosure that can withstand mishaps. Thus, a water-resistantand scratch-resistant enclosure would also be desirable.

Therefore, it would be beneficial to provide improved enclosures forportable computing devices, particularly enclosures that are functionaland aesthetically pleasing yet durable. In addition, there is a need forimprovements in the manner in which structures are mounted within theenclosures. For example, improvements that enable structures to bequickly and easily installed within the enclosure, and that helpposition and support the structures in the enclosure.

SUMMARY OF THE DESCRIBED EMBODIMENTS

This paper describes various embodiments that relate to systems,methods, and apparatus for providing an enclosure suitable for aportable computing device. In particular, at least portions of theenclosure can be transparent or at least translucent and as such can beformed of materials such as glass. It will be understood that theenclosure can be formed of glass but does not need to have anytransparent portion. In other words, the entire glass enclosure can beopaque. In other embodiments, the glass enclosure can be fullytransparent or partially transparent or translucent.

According to one embodiment, a portable computing device capable ofwireless communications is described. The portable computing deviceincludes an integral and substantially seamless enclosure that surroundsand protects the internal operational components of the portablecomputing device. The enclosure includes a tube like main body that isextruded in its entirety with glass material that permits wirelesscommunications therethrough.

According to another embodiment, a portable electronic device isprovided. The portable electronic device includes a substantiallyseamless enclosure that surrounds and protects the internal operationalcomponents of the portable electronic device. The enclosure alsoincludes at least one structural wall formed from a glass material.

According to yet another embodiment, a method for manufacturing aportable electronic device capable of wireless communications isdisclosed. The portable electronic device surrounds and protectsinternal operation components. The method can be carried out by thefollowing operations: providing an integral and substantially seamlessenclosure extending along a longitudinal axis, sliding at least oneoperational component into an internal lumen defined by the enclosure,and securing the operational component to the lumen when the operationalcomponent is in its desired position within the lumen. The enclosureincludes a structural wall defining a shape or form of the portableelectronic device and is formed from a glass material that permitswireless communications therethrough.

Other aspects and advantages of the invention will become apparent fromthe following detailed description taken in conjunction with theaccompanying drawings which illustrate, by way of example, theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1 is an exploded perspective diagram of an electronic device, inaccordance with one embodiment.

FIG. 2 is an exploded side view of a touch screen display assembly in aglass enclosure.

FIG. 3 is a side view of a LCD display integrated with a glassenclosure.

FIG. 4 shows an embodiment of end caps for a glass enclosure.

FIGS. 5A and 5B show embodiments of end caps for a glass enclosure.

FIGS. 6A and 6B show embodiments of end caps for a glass enclosure.

FIG. 7 is a side cross-sectional view of a glass enclosure having a wallwith a continuous uniform thickness all around.

FIG. 8 is a side cross-sectional view of a glass enclosure having a wallwith a thicker wall portion at the edge or corner portions.

FIG. 9 is a perspective diagram of a handheld computing device, inaccordance with one embodiment.

FIG. 10 is a front perspective view of a glass seamless enclosure, inaccordance with one embodiment.

FIG. 11 is a top plan view of a glass enclosure co-extruded with both anopaque material and a transparent material, in accordance with oneembodiment.

FIG. 12 is a perspective view of a two-layer clad glass enclosure.

FIG. 13 is a front perspective view of an embodiment of an electronicdevice having an enclosure formed from two glass members bondedtogether.

FIGS. 14A and 14B are a top plan view and perspective view of a glassband, respectively.

FIG. 15 is a side cross-sectional view of a glass enclosure with twoflat pieces of glass bonded to the glass band shown in FIG. 14.

FIG. 16A is a perspective view of a ceramic disk formed around severalmetal rods for forming a water-resistant audio jack in accordance withan embodiment.

FIG. 16B is a top plan view of the water-resistant audio jack shown inFIG. 16A.

FIG. 17 is a method of manufacturing an electronic device with a glassenclosure, in accordance with one embodiment.

FIG. 18 is a perspective view of a solid block of glass prior to beingformed into a glass enclosure.

FIGS. 19 and 20 are side view showing chamfered edges and radius edgesof an embodiment of a glass enclosure.

FIG. 21 is a perspective view of an embodiment of a glass enclosure madeby a deep drawn blow molding process.

FIG. 22 is a side cross-sectional view of a glass main body with inkprinting or back printing to achieve opacity around a display.

FIG. 23 is a perspective view of an embodiment of a glass main bodyhaving textured portions for use as light indicators.

FIG. 24 is a perspective view of a method of sealing of the interior ofa glass enclosure to achieve a thicker surface layer in compression in achemical strengthening process in accordance with an embodiment.

FIG. 25 shows an embodiment of a main body with rails that are adheredto and a screw boss molded into the main body.

DETAILED DESCRIPTION OF SELECTED EMBODIMENTS

Reference will now be made in detail to representative embodimentsillustrated in the accompanying drawings. It should be understood thatthe following descriptions are not intended to limit the embodiments toone preferred embodiment. To the contrary, it is intended to coveralternatives, modifications, and equivalents as may be included withinthe spirit and scope of the described embodiments as defined by theappended claims. It should be noted that issued U.S. Pat. No. 7,515,431“Handheld Computing Device” filed Jul. 2, 2004 by Zadesky et. al., andissued U.S. Pat. No. 7,724,532 “Handheld Computing Device” filed Aug. 7,2006 by Zadesky et. al., (CIP of '431 patent) are both herebyincorporated by reference in their entireties for all purposes.

FIG. 1 is an exploded perspective diagram of an electronic device 50, inaccordance with one embodiment. The device 50 may be sized forone-handed operation and placement into small areas, such as a pocket.In other words, the device 50 can be a handheld pocket-sized electronicdevice. By way of example, the electronic device 50 may correspond to acomputer, media device, telecommunication device, and the like.

The device 50 includes a housing 52 that encloses and supportsinternally various electrical components (including, for example,integrated circuit chips and other circuitry) to provide computingoperations for the device 50. The housing 52 can also define the shapeor form of the device 50. That is, the contour of the housing 52 mayembody the outward physical appearance of the device 50. It should benoted that, although the device 50 is illustrated in FIG. 1 with 90degree edges, it will be understood that the device 50 can have roundedor chamfered edges.

The housing 52 generally includes a main body 54 in the form of anintegral tube. By integral, it is meant that the main body is a singlecomplete unit. By being integrally formed, the main body is structurallystiffer than conventional housings, which typically include two partsthat are fastened together. Furthermore, unlike conventional housingsthat have a seam between the two parts, the main body has asubstantially seamless appearance. Moreover, the seamless housingprevents contamination and is more water resistant than conventionalhousings.

Because of the tube like configuration, the main body 54 can define acavity 56 therethrough between two open ends. In some embodiments, themain body 54 has only one open end. The main body 54 can also includeone or more windows 62, which provide access to the electricalcomponents, particularly the user interface elements, when they areassembled inside the cavity 56 of the main body 54.

The main body 54 may be formed from a variety of materials or materialcombinations including, but not limited to, glass, metals, metal alloys,plastics, ceramics and the like. In a particular embodiment, the mainbody is formed of glass.

The material selected generally depends on many factors including, butnot limited to, strength (tensile), density (lightweight), strength toweight ratio, Young's modulus, corrosion resistance, formability,finishing, recyclability, tooling costs, design flexibility,manufacturing costs, manufacturing throughput, reproducibility, and thelike. The material selected may also depend on electrical conductivity,thermal conductivity, radio wave transparency, combustibility, toxicity,and the like. The material selected may also depend on aesthetics,including color, surface finish, and weight.

In one particular embodiment, the main body or glass enclosure 54, withor without internal rails 80, is formed from a glass tube. The glasstube may be formed from an extrusion or extrusion-like process. Some ofthe reasons for using glass over other materials are that glass isstrong, stiff, and radio transparent and therefore a suitable materialfor an enclosure of an electronic device capable of wirelesscommunications. The radio transparency is especially important forwireless hand held devices that include antennas internal to theenclosure. Radio transparency allows the wireless signals to passthrough the enclosure and, in some cases, even enhances thesetransmissions. It will be understood that, although a glass enclosure iscapable of wireless communications, the embodiments described hereinneed not be capable of wireless communication.

A glass enclosure can also provide the portable electronic device with aunique, aesthetically pleasing appearance. To further provide anaesthetically pleasing appearance, the glass can also be coated with anoleophobic coating to reduce finger prints and smudging on the glass.The glass can also be coated with an anti-reflective coating to reduceglare. It will be understood that chemically strengthened glass can alsobe scratch resistant. The glass can also be color tinted in a widevariety of colors and can also have a variety of surface finishesincluding smooth and rough. For example, the glass can be polished tocreate a smooth (gloss) finish, or a blasting operation can performed tocreate a rough or textured (matte) finish. Portions 480 of the glass canalso be textured so that the textured surface will disperse light andcan be used as light indicator, as shown in FIG. 23.

As discussed in more detail below, the glass material can be formed sothat the enclosure can have a seamless or substantially seamlessappearance. The seamless enclosure, in addition to being aestheticallypleasing, can provide the added benefit of less contamination andmoisture intrusion into the interior of the device.

It should be noted that glass has been used in a wide variety ofproducts, including electronic devices, such as watches, and phones. Inthese cases, however, the glass materials have not been used asstructural components. In most of these cases, the glass materials havebeen used as cosmetic accoutrements or solely as a screen for a display.It is believed that, up until now, glass materials have never been usedas a structural element providing substantially all of the structuralframes, walls and main body of a consumer electronic device, and moreparticularly an enclosure of a portable electronic device, such as amedia player or mobile phone.

The glass enclosure also allows a display screen to be positionedunderneath and protected by the glass enclosure. The glass material ofthe enclosure is capable of capacitive sensing so that a touch screencan be used through the glass enclosure. An embodiment of a touch screendisplay in a glass enclosure 54 is illustrated in FIG. 2, which is anexploded side view of the glass enclosure 54 with a liquid crystaldisplay (LCD) touch screen assembly 120. According to this embodiment,the glass enclosure 54 can have an opening 55 on its rear face oppositethe face with the display. In this embodiment, the entire touch screendisplay assembly 120 can be inserted through the opening 55 and into theenclosure. As shown in FIG. 2, the touch screen display assembly 120includes a double indium tin oxide (DITO) 124 layer sandwiched betweentwo optically clear adhesive (OCA) layers 122, and a LCD 126 over one ofthe OCA layers 122. The top OCA layer 122 can adhere the DITO layer 124to the LCD 126. The bottom OCA layer 122 can adhere the touch screendisplay assembly 120 to the glass enclosure 54. By adhering the touchscreen display assembly 120 directly to the glass enclosure 54, thecover glass of a conventional touch screen display assembly can beeliminated and the device can therefore be thinner as well as moreaesthetically pleasing with a seamless enclosure. In this embodiment,the housing can be sealed with a door or a cap formed of glass or anyother suitable material, including metal, plastic, and ceramic.

The glass enclosure around the display can be made opaque so theoperational components of the device are not visible. One method ofmaking the glass opaque is to use ink printing 128 in the areas whereopacity is desired, as shown in FIG. 2. A mask can be used to mask offthe display area. Alternatively, the opacity can be painted or screenprinted. Other techniques for achieving opacity in certain areas, suchas using a two-layer clad glass, can be used, as will be described inmore detail below.

According to another embodiment shown in FIG. 3, a LCD 130 can beintegrated with the glass enclosure 54. In this embodiment, a colorfilter panel 132 may be positioned between a thin film transistor (TFT)glass 134 and the glass enclosure 54 to form the LCD 130. A conventionalLCD has a color filter panel sandwiched between two TFT glass layers. Inthis embodiment, the glass enclosure 54 is used in place of one of theTFT glass layers. This embodiment therefore allows the device to bethinner, as one less piece of TFT glass is used. It will be understood,that although the embodiment illustrated in FIG. 3 shows an opening inthe enclosure 54, this embodiment of the LCD can be employed in any ofthe embodiments of glass enclosures described herein.

In order to seal the main body 54, the housing 52 can additionallyinclude a pair of end caps or plugs 64A and 64B. Each of the end caps orplugs 64 is configured to cover one of the open ends of the main body54, thereby forming a fully enclosed housing system. In someembodiments, the end caps 64 can be formed of materials, such asplastic, metal, and ceramic. The end caps 64 also serve as protectionfor the edges of the glass main body 54, as will be explained in moredetail below.

As noted above, it is desirable for an enclosure to be durable. A pieceof glass typically breaks due to an exposed edge. For glass materials,crisp, 90 degree edges and corners are prone to failure. Crisp edges caneasily be chipped off and become an origin for crack propagation. Thus,it is important to treat the edges of the glass. The edges can bemachined or buffed to make an edge chamfer 160 (as shown in FIG. 19) oran edge radius 162 to round out the edges (as shown in FIG. 20). Inaddition, the edges can be coated with a protective material. In someembodiments, the exposed ends of the glass enclosure can be covered byapplying protective coatings, such as plated metal using metallizationor PVD plate metal. Alternatively, polymer coatings can be applied overthe exposed glass edges. The end caps 64 can also provide furtherprotection for the glass edges.

Furthermore, the end caps 64 may be attached to the main body 54 using avariety of techniques, including but not limited to, fasteners, glues,snaps, and the like. In some cases, the end caps 64 may be positioned onthe surface of the open ends. If so, they typically have the same shapeas the outer periphery of the main body 54. In order to eliminate gaps,cracks or breaks on the front and side surfaces, the end caps 64 mayalternatively be placed inside the cavity 56 at each of the ends. Inthis arrangement, the outer periphery of the end cap 64 generallymatches the inner periphery of the main body 54. This implementation istypically preferred in order to form a housing 52 with a uniform andseamless appearance, i.e., no breaks when looking directly at the front,back or side of the housing.

FIGS. 4-6 illustrate additional embodiments of end caps 64 for the glassmain body 54. The end caps 64 can cover the open ends of the main body54 in order to provide a fully contained housing 52. Although the endcaps 64 can be applied in a variety or ways, in the particularembodiment shown in FIG. 4, the end caps 64 have a shape that coincideswith the internal shape of the main body 54 such that a portion of theend caps 64 may be inserted into the open ends. In FIG. 5B, the end caps64 do not fully cover the open ends, but do provide protection to theedge of the main body 54. In the embodiment shown in FIG. 5B, a feature,such as a door, can be used to fully cover an open end of the main body54. FIG. 6B is a perspective view of an end cap 64 shown in the sideview of FIG. 6A.

The cross-sectional shape, including both the outer and inner shapes, ofthe main body 54 may be widely varied. They may be formed from simple orintricate shapes, whether rectilinear and/or curvilinear. For hand helddevices, it is typically preferred to use a shape that better fits thehand (e.g., form fits). By way of example, a rectangle with curved edgesor an oval or pill shaped cross section having curvature that moreeasily receives the hand may be used. It should be noted that the innercross-sectional shape may be the same or different from the externalcross sectional shape of the main body. For example, it may be desirableto have a pill shaped external and a rectangular shaped interior, etc.In addition, although not a requirement, the front surface of the mainbody 54 may be substantially planar for placement of the user interfaceof the device 50.

In some embodiments, the main body 54 can have a wall having acontinuous uniform thickness all around, as shown in FIG. 7. In otherembodiments, as shown in FIG. 8, the wall of the main body 54 can bethicker at the edge or corner portions to provide strength in the areaswhere strength is more needed.

The seamless main body 54 can extend along a longitudinal axis, and caninclude an internal lumen that is sized and dimension for receipt of theinternal components of the device 50 through an open end of the mainbody 54. The device 50 can also include one or more electronicsubassemblies. The subassemblies can each include a carrier 68 and oneor more operational components 70 of the electronic device 50. Thecarrier 68 can provide a structure for carrying the operationalcomponents 70 and supporting them when assembled inside the housing 52.By way of example, the carrier 68 may be formed from plastics, metals,or a printed circuit board (PCB). The operational components 70, on theother hand, perform operations associated with the computing device 50.The operational components 70 may, for example, include components suchas user interface elements 70A and circuit elements 70B. The userinterface elements 70A allow a user to interact with the computingdevice 50. By way of example, the user interface elements 70A maycorrespond to a display or an input device, such as a keypad, touch pad,touch screen, joystick, trackball, buttons, switches and the like. Thecircuit components 70B, on the other hand, perform operations, such ascomputing operations for the computing device 50. By way of example, thecomputing components 70B may include a microprocessor, memory, harddrive, battery, I/O connectors, switches, power connectors, and thelike.

During assembly, the subassemblies are positioned inside the cavity 56of the main body 54. In particular, the subassemblies can be insertedinto an open end of the main body 54 mainly along a longitudinal axis 74of the main body 54 to their desired position within the housing 52.Once the subassemblies are positioned inside the cavity 56, the end caps64 of the housing 52 may be attached to the main body 54 in order tofully enclose the housing 52 around the subassemblies. In most cases,the user interface elements 70A are positioned relative to the windowopening 62 so that a user may utilize the user interface elements 70A.By way of example, the window 62 may allow viewing access to a displayor finger access to a touch pad or button. However, as discussed above,the glass main body 54 is capable of capacitive sensing, so a touchscreen or a touch pad could be positioned underneath the glass enclosurewithout a window opening 62.

In order to more efficiently assemble the electronic subassemblies 66inside the cavity 56, the device 50 may include an internal rail system78 disposed inside the cavity 56 of the main body 54. In most cases, theinternal rail system 78 is integrally formed with the main body 54,i.e., formed as a single part. In some embodiments, as shown in FIG. 25,the rail system 78 can be adhered to the main body 54. Features, suchthe internal rails 80 and screw bosses 79, for mounting subassembliescan be adhered or molded into the main body 54.

The internal rail system 78 is configured to receive the varioussubassemblies and guide them to their desired position within the mainbody 54 when the subassemblies are inserted through one of the openends. The internal rail system 78 enables the subassemblies to be easilyand quickly assembled within the device 50. For example, the rail system78 provides for insertion (or removal) with minimal effort and withouttools. The internal rail system 78 also helps support and store thesubassemblies in an organized manner within the device 50. By way ofexample, the rail system 78 may store the subassemblies in a stackedparallel arrangement thereby using available space more efficiently.

In the illustrated embodiment, the rail system 78 includes at least oneset of opposed rails 80, each of which extends longitudinally throughthe cavity 56 and each of which protrudes from the inner sides of themain body 54. The rails 80 are configured to receive the subassembliesand cooperate to guide subassemblies to their desired position withinthe housing 52. The internal rails 80 generally allow the subassembliesto be slid into the cavity 56 through an open end following thelongitudinal axis 74 of the main body 54. That is, the subassemblies arecapable of sliding in and out of the housing 52 along one or moresurfaces of the rails 80.

The portion of the subassemblies that engages the rails 80 may be asurface of the subassemblies or alternatively one or more posts ormounts that extend outwardly from the subassemblies. Furthermore, thereference surfaces for the opposed rails 80 may be positioned in thesame plane or they may be positioned in different planes. Theconfiguration generally depends on the configuration of thesubassemblies. By way of example, in some cases, the subassemblies mayhave a cross section that is stepped rather than completely planar. Incases such as these, the opposed rails 80 have references surfaces indifferent planes in order to coincide with the stepped cross section.Moreover, although typically continuous between the ends, each of therails 80 may be segmented or include removed portions as for example atthe ends for placement of the flush mounted end caps.

The width of the rails 80 may be widely varied. For example, they may beone integral piece that extends entirely from one side to the other, orthey may be separate pieces with a gap located therebetween (as shown).The position and cross sectional dimensions and shapes of each of therails may also be widely varied. The size and shape as well as theposition of the rails 80 generally depend on the configuration of thesubassemblies. The rails 80 may have the same shape and size or they mayhave different shape and size. In most cases, the size and shape is abalance between keeping them as small as possible (for weight and spacerequirements) while providing the required reference surface and amplesupport to the subassemblies.

To elaborate, the rails 80 define one or more channels 82 that receivethe one or more subassemblies. In the illustrated embodiment, the rails80 along with the main body 54 define a pair of channels, particularlyan upper channel 82A and a lower channel 82B. The upper channel 82Areceives a first subassembly 66A and the lower channel 82B receives asecond subassembly 66B. It should be noted, however, that this is not alimitation and that additional sets of rails 80 may be used to produceadditional channels 82. It should also be noted that although only onesubassembly is shown for each channel 82, this is not a requirement andthat more than one subassembly may be inserted into the same channel 82.Moreover, it should be noted that the subassemblies are not limited tobeing fully contained with a single channel and that portions of asubassembly may be positioned in multiple channels. For example, thesecond subassembly 66B, which is positioned in the lower channel 82B,may include a protruding portion that is positioned through the rails 80and into the upper channel 82A.

The channels 82 generally include an entry point and a final point. Theentry point represents the area of the channel 82 that initiallyreceives the subassemblies 66, i.e., the area proximate the ends of themain body 54. The final point, on the other hand, represents the area ofthe channel 82 that prevents further sliding movement. The final pointmay, for example, set the final mount position of the subassemblies 66within the housing 52. The final point may, for example, correspond toan abutment stop. The abutment stop may be integral with the main body54 or a separate component. By way of example, the abutment stop maycorrespond to one more posts that are mounted inside the cavity 56 onthe inside surface of the main body 54 at a predetermined distance alongthe longitudinal axis 74.

In order to prevent the subassemblies 66 from sliding once assembled,the interface between the subassemblies 66 and housing 52 may include alocking or securing mechanism. The locking mechanism generally consistsof two parts, including a housing side locking feature and a subassemblyside locking feature that are cooperatively positioned so that when thesubassembly 66 is inserted into the housing 52, the locking featuresengage with one another thus holding the subassembly 66 in its desiredposition within the housing 52. In most cases, the locking features areconfigured to provide quick and easy assembly of the subassembly intothe housing without the use of tools. The locking features maycorrespond to snaps, friction couplings, detents, flexures and/or thelike. Alternatively or additionally, the subassemblies 66 may beattached to the main body 54 with fasteners or adhesives. In otherembodiments, the operational components 70 can be directly secured tothe main body 54.

In the illustrated embodiment, the locking features of the subassemblies66 each include a flexure tab 88 that engages a recess 90 located on aninner surface of the main body 54. When the subassembly 66 is slid intothe housing 52, the tab 88 snaps into the recess 90 thereby securing thesubassembly 66 at a predetermined position along the longitudinal axis74. That is, because the tabs 88 flex, they allow the subassemblies 66to pass when pushed into the cavity 76. When the subassemblies 66 passover the recess 90, the tabs 88 resume their natural position therebytrapping the subassemblies 66 in the channel 82 between the lockingtab/recess 88/90 and the abutment stop at the end of the channel 82.Using this arrangement, the subassemblies 66 are prevented from slidingout of the channels 82 on their own. In order to remove the subassembly66, a user simply lifts the tab 88 away from the recess 90 while pullingon the subassembly 66. The recess 90 and abutment stop may cooperate toset the final position of the subassembly 66 in the cavity 56 of themain body 54. For example, the recess and abutment stop may beconfigured to position the user interface elements 70A directly behindthe window opening 62 so that a user has full access to the userinterface elements 70A.

In accordance with one embodiment, the main body 54, which may includethe internal rails 80 (or other internal features), is formed via anextrusion or extrusion-like process. The process is capable of producingan integral tube without seams, crack, breaks, and the like. As isgenerally well known, extrusion of conventional materials, such asmetals and plastics, is a shaping process where a continuous work piece(i.e., a solid block of glass 10 as shown in FIG. 18) is produced byforcing molten or hot material through a shaped orifice. The extrusionprocess produces a length of a particular cross sectional shape. Thecross-sectional shape of the continuous or length of the extruded workpiece is controlled at least in part on the shaped orifice. As theshaped work piece exits the orifice, it is cooled and thereafter cut toa desired length.

FIG. 9 is a perspective view of a handheld computing device 100, inaccordance with one embodiment. By way of example, the computing device100 may generally correspond to the device 50 shown and described inFIG. 1. The computing device 100 is capable of processing data and moreparticularly media, such as audio, video, images, and the like. By wayof example, the computing device 100 may generally correspond to a musicplayer, game player, video player, camera, cell phone, personal digitalassistant (PDA), and the like. With regard to being handheld, thecomputing device 100 can be operated solely by the user's hand(s), i.e.,no reference surface, such as a desktop, is needed. In some cases, thehandheld device is sized for placement into a pocket of the user. Bybeing pocket sized, the user does not have to directly carry the deviceand therefore the device can be taken almost anywhere the user travels(e.g., the user is not limited by carrying a large, bulky and heavydevice). In the illustrated embodiment, the computing device 100 is apocket-sized hand held music player that allows a user to store a largecollection of music. By way of example, the music player may correspondto the iPod series MP3 players, including for example the iPod Mini™ andiPod Nano™ manufactured by Apple Inc. of Cupertino, Calif.

As shown, the computing device 100 includes a housing 102, which can beformed of glass, which encloses and supports internally variouselectrical components (including integrated circuit chips and othercircuitry) to provide computing operations for the device. Theintegrated circuit chips and other circuitry may include amicroprocessor, hard drive, Read-Only Memory (ROM), Random-Access Memory(RAM), a battery, a circuit board, and various input/output (I/O)support circuitry. In addition to the above, the housing 102 may alsodefine the shape or form of the device 100. In this particularillustrated embodiment, the housing 102 extends longitudinally and has apill like cross section. The size and shape of the housing 102 ispreferably dimensioned to fit comfortably within a user's hand. In oneparticular embodiment, the housing is formed from a glass material andhas a seamless or substantially seamless look along the length of thedevice 100. That is, unlike conventional housings, the housing 102,particularly the main body, does not include any breaks between the topand bottom ends, thereby making it stiffer and more aestheticallypleasing.

The computing device 100 can also include a display screen 104. Thedisplay screen 104, which is assembled within the housing 102 and whichcan be visible through the glass housing 102 or can be positioned in awindow 106, can be used to display a graphical user interface (GUI) aswell as other information to the user (e.g., text, objects, graphics).The display screen 104 can also employ touch screen technology. As notedabove, the glass material of the housing 102 allows the display screen104 to be positioned underneath and protected by the glass housing 102.The glass material of the housing 102 is also capable of capacitivesensing so that a touch screen or touch pad can be used through theglass housing 102.

The computing device 100 can also include one or more input devices 108configured to transfer data from the outside world into the computingdevice 100. The input devices 108 may, for example, be used to performtracking or scrolling to make selections or to issue commands in thecomputing device 100. By way of example, the input devices 108 maycorrespond to keypads, joysticks, touch screens, touch pads, trackballs, wheels, buttons, switches, and the like. In the embodimentillustrated in FIG. 9, the computing device 100 includes a touch pad108A and one or more buttons 108B, which are assembled within thehousing 102 and which are accessible through an opening 110 in thehousing 102.

The touch pad 108A generally consists of a touchable outer surface 111for receiving a finger for manipulation on the touch pad 100A. Althoughnot shown, beneath the touchable outer surface 111 is a sensorarrangement. In an embodiment, the sensor arrangement may be positioneddirectly underneath the glass enclosure without the touchable outersurface 111, as the glass is capable of capacitive sensing and can actas the touchable outer surface. The sensor arrangement includes aplurality of sensors that are configured to activate as the fingerpasses over them. In the simplest case, an electrical signal is producedeach time the finger passes a sensor. The number of signals in a giventime frame may indicate location, direction, speed and acceleration ofthe finger on the touch pad, i.e., the more signals, the more the usermoved his or her finger. In most cases, the signals are monitored by anelectronic interface that converts the number, combination and frequencyof the signals into location, direction, and speed and accelerationinformation. This information may then be used by the device 100 toperform the desired control function on the display screen 104.

The buttons 108B are configured to provide one or more dedicated controlfunctions for making selections or issuing commands associated withoperating the device 100. In most cases, the button functions areimplemented via a mechanical clicking action although they may also beassociated with touch sensing similar to the touch pad 108A. Theposition of the buttons 108B relative to the touch pad 108A may bewidely varied. Several touch pad/button arrangements, which may be usedin the device 100, are described in greater detail in U.S. patentapplication Ser. Nos. 10/643,256, 10/188,182, 10/722,948, which are allhereby incorporated by reference herein in their entireties. Thecomputing device 100 can also include one or more switches 112,including power switches, hold switches, and the like. Like the touchpad 108A and buttons 108B, the switches 112 can be accessible through asecond opening 114 in the housing 102.

The device 100 may also include one or more connectors 116 fortransferring data and/or power to and from the device 100. In theillustrated embodiment, the device 100 includes an audio jack 116A, adata port 116B and a power port 116C. In some cases, the data port 116Bmay serve as both a data and power port thus replacing a dedicated powerport 116C. A data port such as this is described in greater detail inU.S. patent application Ser. No. 10/423,490, which is herebyincorporated by reference herein in its entirety.

In order to provide user access to an input assembly, such as a touchpad or touch screen display, the glass main body 54 can include anaccess opening or window 62 having a shape that coincides with the shapeof the input assembly. As shown in FIG. 10, the access openings 62 forthe display and touch pad can be located in the front planar surface280. The access openings 62 may be formed from processes (individuallyor in combination), such as machining, drilling, cutting, punching, andthe like. In embodiments having the access openings 62, some of theoperational components may be loaded into the enclosure through theaccess openings 62.

As noted above, the access openings 62 may provide user access tocomponents, such as displays, touch pads, and buttons. Another way toprovide access to a display is through the transparent glass enclosure.However, it can be appreciated that it is generally not desirable forthe entire enclosure to be transparent because the internal operationalcomponents are usually not aesthetically pleasing. Thus, as discussedabove, opacity (or translucency) around components, such as displays, isdesirable. One way to achieve opacity is by ink printing or backprinting the glass, as described above. FIG. 22 is a sidecross-sectional view of a glass main body 54 with ink printing or backprinting 450 to achieve opacity around a display. As shown in FIG. 22,the printing 450 does not go all the way around the main body 54 so asto leave an area or transparency 460 for the display.

Another way to achieve opacity around a display or other component is toform the main body 54 by co-extruding an opaque glass material 146together with a transparent glass material 148, as shown in FIG. 11. Thedotted lines in FIG. 11 illustrate the separation between the opaquematerial 146 and the transparent material 148. As shown in FIG. 11, theaccess opening or window 62 for the display is in the transparentmaterial 148 portion.

Yet another way to achieve opacity around a component, such as adisplay, is to use a two-layer clad glass 140 for the main body 54, asshown in FIG. 12. The clad glass 140 is formed by fusing together alayer of opaque glass material 142 and a layer of transparent glassmaterial 144 at a high temperature. The two layers 142, 144 will cool asa single fused layer. If the opaque glass material 142 is positioned asthe external layer and the transparent glass material 144 is positionedas the internal layer, then a portion of the opaque glass 142 can beetched, or otherwise removed, to expose a portion of the transparentglass 144 underneath to form a window for the display.

Another benefit of using a two-layer clad glass 140 is that theenclosure can be made stronger if the glass includes two layers havingdifferent coefficients of thermal expansion (CTE). If the external layerhas a high CTE and the internal layer has a low CTE, then the two layers142, 144 will fuse into one layer, with the external surface glass layer142 being in a compressive state. The skilled artisan will appreciatethat glass is stronger in compression and weaker in tension, and thedifferent cooling rates of the two layers of glass will result in theexternal surface layer 142 being in compression and therefore stronger.

Typically, a sheet of glass can be made stronger by chemicallystrengthening it. For example, the glass can be placed in a potassiumbath to cause the entire surface of the glass to be in a compressedstate and therefore stronger. Thus, a glass enclosure, as describedherein, having a single layer of glass material could be chemicallytreated to improve the strength of the glass. However, potassium bathsare expensive, so using a two-layer clad glass with layers that havedifferent CTEs can provide cost savings. Thus, by using a two-layer cladglass 140, opacity in desired portions can be achieved and the glassenclosure can be made stronger without employing an expensive potassiumbath.

FIG. 24 is a perspective view illustrating a method of sealing of theinterior of a glass enclosure to achieve a thicker surface layer incompression in a chemical strengthening process, in accordance with anembodiment. According to this embodiment, a thicker layer of compressionon the external surface of the glass main body 54 is achieved. Thisthicker layer of compression on the external surface is relative to theinternal surface of the main body 54. In the illustrated embodiment, theexternal surface of the glass main body 54 can be made even stronger bysealing the open ends of the main body 54 to close off the interior ofthe main body 54 with seals 650 and placing the sealed off glass mainbody 54 in a potassium bath to compress only the exterior of the tubeand not the interior. By compressing only the external surface of theglass main body 54 so that the interior of the main body 54 remains notchemically strengthened, a thicker layer of compression on the externalsurface can be achieved. It will be understood that any suitable methodfor sealing off the interior may be employed to achieve a thicker layerof compression on the external surface.

Although not shown, the internal components may also include componentsfor processing, transmitting and receiving wireless signals (e.g.,transmitter, receiver, antenna, etc.) through the glass enclosure 54. Byway of example, the device may include components for supporting FM, RF,Bluetooth, 802.11, and the like. In one embodiment, the device caninclude functionality for supporting cellular or mobile phone usage. Inthis embodiment, the device includes processors, transmitters,receivers, and antennas for supporting RF, and more particularly GSM,DCS and/or PCS wireless communications in the range of about 850 toabout 1900 MHz. The device may, for example, include one or moreantennas tuned to operate over the GSM, PCS and/or DCS frequency bands.By way of example, monopole, dipole and tri band and quad band antennasmay be used. In one example, a PCS+DCS dipole antenna is used. Theantenna may protrude out of the enclosure or it may be fully enclosed bythe enclosure. If the latter, the glass enclosure is radio transparentand therefore capable of transmitting and receiving RF signalstherethrough.

As described above, the main body of the enclosure can be formed from aglass material that is radio-transparent. By utilizing a glass enclosurethat is radio-transparent, an internal antenna may be used, which istypically more robust and durable than an external antenna. Furthermore,many advantages regarding the use of an internal antenna may beachieved. For example, a smaller and cheaper antenna may be used.Moreover, the antenna can be integrated with other components and placedat almost any location within the enclosure, which helps make a smallerand more compact device in addition to reducing the cost of manufacture.An example of wireless communication devices and mechanisms can be foundin U.S. patent application Ser. No. 10/423,490, which is herebyincorporated by reference herein in its entirety.

In another embodiment shown in FIG. 21, the glass enclosure 400 can beformed using a deep drawing and a blow molding process. The deep drawingand blow molding processes result in a bucket or cup-like glassenclosure 400 with only one open end 410, as shown in FIG. 21.Therefore, only one end cap 64 is necessary to close off or seal suchhousing.

FIG. 13 shows one embodiment of an enclosure 550 that includes a topmember 552 with a bottom member 554 attached thereto. The top and bottommembers 552 and 554 can be formed from the same or different materials.In one embodiment, the top and bottom members 552, 554 are both formedof glass. As should be appreciated, any combination can be used.Furthermore, this design can be made with or without using end caps. Forexample, the top and bottom members may include a closed end. Accordingto the embodiment shown in FIG. 13, the two members 552, 554 allowcomponents to be assembled onto the members 552, 554 before the twomembers 552, 554 are bonded together using, for example, an adhesive orlaser frit bonding. For example, if both members 552, 554 are glass, thelaser frit bonding may be employed to hermetically seal the two members552, 554 together to form the enclosure 550. Ink printing or backpainting to achieve opacity in certain areas can also he performed priorto assembling the components and bonding the members 552, 554 together.After the two members 552, 554 are bonded together; the enclosure 550can be polished so that the enclosure 550 has a more continuous andsubstantially seamless appearance. If no openings are provided in theenclosure 550, then a laser frit bonded enclosure 550 can be fullyhermetically sealed and therefore water resistant, as will be describedin more detail below.

FIGS. 14A and 14B are a top plan view and perspective view of a glassband 610 according to an embodiment. According to an embodiment, theglass band 610 is formed by an extrusion process and then cut to thedesired height. In the illustrated embodiment shown in FIG. 15, to formthe housing 600, the glass band 610 is laser frit bonded to two flatpieces of glass: a cover glass 620 and a back glass 630 to form ahermetic seal. In another embodiment, the glass band 610 can be bondedto a cover glass 620 and a back plate (not shown).

Because the cover glass 620 and back glass 630 are laser frit bonded tothe glass band 610, the embodiment of the housing 600 shown in FIG. 15can be made fully hermetically sealed if the housing 600 is not providedwith any access openings. As discussed above, the glass housing iscapable of capacitive sensing, so components such as touch screens andtouch pads can be positioned underneath the glass enclosure. Othercontrols, such as buttons for volume control or power, can also bepositioned underneath the glass enclosure by placing capacitive sensorsunderneath the glass housing so that openings for buttons areunnecessary. Speakers and microphones may be provided with a GORETEX®membrane, which is waterproof. The device can send and receive signalsusing wireless signals, which can be transmitted through the radiotransparent glass housing 600.

If a method of transferring electric signals through an impermeable wallis desired for the embodiment shown in FIG. 15, a component such as theone shown in FIG. 16 can be provided to maintain the water resistantcharacteristic of the device. The electrical signal transferringcomponent 700 is made by forming a ceramic disk 710 around several metalrods 720, as shown in FIG. 16A. These metal rods are then shaved down ormachined away to leave metal contacts 720 in the ceramic disk, therebyforming the water resistant audio jack, as shown in FIG. 16B. It will beunderstood that the metal contacts 720 serve as electrical contacts. Thecomponent 700 can be used to receive signals from an audio jack and passthem into a water-resistant device, such as the one shown in FIG. 15,such that no water can get through this geometry, but the electricsignals can.

According to another embodiment, a display screen can be built into theglass enclosure. LCDs are typically formed with a carrier. However, theglass enclosure can be used as the carrier for the display, therebydecreasing the bulk of the device. It will be understood that such adisplay screen can only be built into an enclosures formed by bondingtogether two members, such as the one illustrated in FIG. 13.

It should be noted that the invention is not limited to this particularform factor. For example, the cross-sectional shape, width, thickness,and height of the enclosure can all be adjusted according to the needsof the device. For example, in some cases, the width and thickness maybe reduced while increasing the height. In addition, the openings in theenclosure can also be modified and may take on other shapes. Forexample, the touch pad circle may be decreased in diameter. In oneexample, the enclosure may have dimensions similar to the iPod Nanomanufactured by Apple Inc. of Cupertino, Calif.

It should also be noted that completely different form factors may beused. For example, the device may correspond to smaller more compactdevices, such as the Shuffle and remote controls manufactured by AppleInc. of Cupertino, Calif.

FIG. 17 is a method of manufacturing an electronic device with a glassenclosure, in accordance with one embodiment. The glass enclosure may beembodied in various forms including those previously mentioned. Themethod begins at block 1700, where a hollow glass tube is provided. Itwill be understood that the glass may be tinted a desired color or madeopaque or translucent in certain areas. The tube can have anycross-sectional shape to create the desired shaped enclosure formed fromglass.

Thereafter, in block 1710, the glass enclosure can be machined to createholes and features into the enclosure, such as, for example, theopenings in the front face of the enclosure. For example, a CNC machinemay be used to perform some or all of the machining operations.Alternatively, the openings and features may be made with laser cutting,jet cutting, ultrasonic cutting, chemical etching, or any other suitablematerial removal operation.

Thereafter, in block 1720, the edges of the glass tube are treated bycreating chamfered or radius edges. In block 1730, a surface finishingoperation may be performed. In one embodiment, a polishing operation canbe performed to create a smooth (gloss) finish. In another embodiment, ablasting operation can be performed to create a rough (matte) finish.

In some cases, the method may include an additional step 1740 ofapplying a protective coating or protective features to the outside ofthe glass enclosure. This may be performed before or after placement ofthe internal components. The coatings or features may, for example, beformed from deformable materials, such as silicon, foam and rubbermaterials. The coatings or protective features are typically positionedon the exterior surface to prevent cracking and protect the glassenclosure from undesirable forces as, for example, when the glassenclosure is dropped. The coatings and protective features can be placedalmost anywhere on the glass enclosure, but in most cases are placed atleast at the edges where the glass enclosure may be susceptible tocracking. In some cases, the end plates may even serve this function.

The method then proceeds to block 1750 where the enclosure is cleanedand inspected. The inspection may include micro photography as well aschemical composition analysis. When approved, the enclosure can be usedto assemble the final product (e.g., internal components insertedinside) in block 1760. In step 1770, the end caps are placed on the openends to seal the housing.

Although the invention has been primarily directed at a single enclosure(except for the end plates), it should be appreciated that, in somecases, the enclosure may be formed from multiple parts rather than asingle integrally formed piece. Each of these parts may be extruded orotherwise formed. Furthermore, they may be formed from the samematerials (glass/glass), same class of materials (first glassmaterial/second glass material) or from different classes of materials(glass/metal, glass/plastic, plastic/metal or glass/plastic/metal). Byway of example, it may be beneficial to combine materials to obtainadvantages of each of the materials. Any combination may be used.Moreover, the multiple parts may include frame components with platesattached thereto, or a top member and a bottom member that are attachedtogether. The attachment means may be widely varied and may include suchthings as fasteners, glues, epoxies, double sided tape, snaps,mechanical interlocks that are molded together, and the like. Oneexample of connecting parts together can be found in U.S. Pat. No.7,012,189 and U.S. application Ser. No. 10/928,780, both of which arehereby incorporated by reference herein in their entireties.

Moreover, although not shown, the various components of the enclosuremay consist of multiple layers that are glued, press fit, molded orotherwise secured together. In one example, the enclosure consists ofmultiple layers that form a single laminate structure formed for exampleby gluing. By way of example, the entire or portions of the enclosurewalls may be formed from layers of metals, ceramics and/or plastics. Inthe case of radio transparency, the layers may include glass andceramics as, for example, forming a wall with a glass outer layer and aceramic inner layer (or vice versa).

Generally speaking, when using an internal antenna, it is desirable toincrease the radio transparency of the enclosure in order to effectivelyperform wireless transmissions therethrough. Thus, a substantial portionof the enclosure is formed form materials capable of providingradio-transparency (e.g., glass, ceramics, plastics, etc.). In mostcases, the radio transparent portions of the enclosure constitute asignificant area of the entire enclosure, for example, greater than 50%,more particularly greater than 75%, and even more particularly greaterthan 85%. The radio transparent portions may even be greater than 90%,and more particularly greater than 95%, and in some cases 100% of theenclosure.

The radio transparent portions may be embodied in a variety of ways. Inone embodiment, the radio transparent portions constitute the entireenclosure. For example, all the walls of the enclosure are radiotransparent (e.g., both the main body and the end caps). In anotherembodiment, the radio transparent portions constitute one or more wallsof the housing, such as, for example, the top and/or bottom member ofthe enclosure shown in FIG. 13. In another embodiment, the radiotransparent portions may constitute a part of one or more walls of theenclosure. That is, only a portion of a wall may be radio transparent.For example, the wall may be separated into two parts, or in the case ofa laminated wall, some portion of the wall may include a non radiotransparent layer.

It is generally believed that a greater area of radio transparencyproduces a stronger signal during transmissions and stronger receptionwhen a signal is received. However, other factors may play a role as forexample the location of the internal antenna. By way of example, in anenclosure with a decreased amount of radio transparency, the internalantenna may be positioned closer or proximate to the radio transparentportions of the enclosure. Furthermore, it should be noted that althoughnon radio transparent portions such as metals typically degrade radiotransmissions, in some cases, non radio transparent portions may bedesigned in such a manner as to enhance or help radio transmissions.

While this invention has been described in terms of several preferredembodiments, there are alterations, permutations, and equivalents, whichfall within the scope of this invention. For example, although someembodiments include an integrally formed internal rail system, in somecases the internal rail system may be a separate component that isattached within the main body or it may not even be included in somecases. It should also be noted that there are many alternative ways ofimplementing the methods and apparatuses of the present invention. Forexample, although an extrusion process is preferred method ofmanufacturing the integral tube, it should be noted that this is not alimitation and that other manufacturing methods may be used in somecases (e.g., injection molding, press forming). In addition, althoughthe invention is directed primarily at portable electronic devices suchas media players, and mobile phones, it should be appreciated that thetechnologies disclosed herein can also be applied to other electronicdevices, such as remote controls, mice, keyboards, monitors, andaccessories for such devices. It is therefore intended that thefollowing appended claims be interpreted as including all suchalterations, permutations, and equivalents as fall within the truespirit and scope of the present invention.

1. A portable computing device, the portable computing devicecomprising: an integral and substantially seamless enclosure thatsurrounds and protects internal operational components of the portablecomputing device, the enclosure including a tube like main body that isextruded in its entirety with glass material that permits wirelesscommunications therethrough.
 2. The portable computing device as recitedin claim 1, further comprising a liquid crystal display touch screenassembly positioned underneath the tube like main body.
 3. The portablecomputing device as recited in claim 1, wherein the portable computingdevice is a handheld computing device.
 4. The portable computing deviceas recited in claim 3, wherein the handheld computing device is a mobilephone.
 5. The portable computing device as recited in claim 3, whereinthe handheld computing device is a media player.
 6. The portablecomputing device as recited in claim 1, further comprising an internalantenna disposed inside the enclosure.
 7. The portable computing deviceas recited in claim 1, further comprising an end cap positioned on anopen end of the enclosure.
 8. The portable computing device as recitedin claim 7, wherein operational components are enclosed by the enclosureand end cap.
 9. A portable electronic device, comprising: asubstantially seamless enclosure that surrounds and protects internaloperational components of the portable electronic device, the enclosureincluding at least one structural wall formed from an extruded glassmaterial.
 10. The portable electronic device as recited in claim 9,wherein a significant portion of the entire enclosure is formed from theglass material.
 11. The portable electronic device as recited in claim9, wherein the enclosure includes an extruded tube of the glassmaterial, and at least one end cap that closes an end of the extrudedtube of glass material.
 12. The portable electronic device as recited inclaim 9, wherein the substantially seamless tube has a first open endand a second open end opposite the first open end, the substantiallyseamless enclosure defining an internal lumen which is sized anddimensioned for insertion of operational components of the portableelectronic device.
 13. The portable electronic device as recited inclaim 12, wherein the lumen includes internal rails for guiding theoperational components to their desired position within the lumen. 14.The portable electronic device as recited in claim 12, wherein thesubstantially seamless enclosure has a substantially planar frontsurface, the planar front surface being configured to present a userinterface subsystem of the handheld computing device, the open endsbeing configured to receive the user interface sub system therethroughduring assembly of the handheld computing device.
 15. The portableelectronic device as recited in claim 14, wherein the lumen includesinternal rails for guiding the operational components to their desiredposition within the lumen, and wherein the internal rails beingconfigured to locate the user interface sub system in its desiredposition relative to the planar front surface of the enclosure duringassembly of the handheld device.
 16. The portable electronic device asrecited in claim 14, wherein the user interface sub system includes adisplay and a touch pad. 17-24. (canceled)